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HITACHI 6HK1 ENGINE Service Repair Manual

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General Information 0A-1GENERAL INFORMATION General Information Contents General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Precautions .…
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General Information 0A-1GENERAL INFORMATION General Information Contents General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2 Reading the model . . . . . . . . . . . . . . . . . . . . . . . 0A-6 General information . . . . . . . . . . . . . . . . . . . . . . 0A-70A-2General InformationGeneral Information Service Precautions In order to carry out work safely 1. Always use an engine stand when taking the engine down from the vehicle. Do not place the engine directly onto the ground, or place in a manner that interferes with the oil pan. 2. If you are working together with others, always pay attention to each other's safety. 3. If you are repairing any part of the electrical system, always remove the minus side cable from the battery terminal before starting work. If you are removing the battery cover, always remove the cover in a place that is away from sources of fire/ heat. WSHK01906. All regular tools, gauges and special tools should be regularly inspected, and prepared before starting work. Do not use bent spanners, hammers with damaged edges, chipped chisels, or any other faulty or damaged tools.4. Do not perform painting work or leave the engine running for long periods of time in an enclosed or badly ventilated indoor workshop. 5. Always use the correct specialized tool indicated in the instructions. Using the incorrect tool may cause damage to the parts or injury to the person using the tool. 7. Always pay close attention to safety and handling requirements when using grinders, cranes, welders, and other such equipment. Moreover, always wear the correct protective garments and use the necessary safety tools for the job in hand.General Information 0A-3WSHK0192WSHK01918. Always check that there are no fuel leaks when performing maintenance work on the fuel system. (It may cause a fire.)Replacement parts and part numbers. 1. Always replace packing, oil seals, o-rings, caulking lock nuts, folding lock plates, split pins and other such parts with brand new parts. 2. The parts numbers contained in this manual may not represent the supply condition of the parts, and the part numbers may be changed due to revisions. Therefore, parts should always be checked against a parts catalogue before use. Liquid gasket9. Pay close attention to the risk of ignition if you are handling parts that carry a high voltage. Furthermore, any oil or grease spilt onto rubber parts must be wiped off immediately, as it will cause deterioration of the rubber.1. Each time you disassemble parts that use liquid gasket, completely remove the old gasket residue from each of the parts and matching sections using a scraper, then clean each of the parts to completely remove oil, water, and dirt etc. from the various surfaces. Using the specified type of liquid gasket, apply new liquid gasket to each of the surfaces before reassembling the parts. 2. In order to make it easier to clean liquid gasket surfaces, apply gasket remover liquid (Pando391D made by Three Bond Co., Ltd.) and leave the part to stand for approximately 10 minutes, after which the old liquid gasket residue will be easier to remove. However, this should not be used on resin components or painted components. 3. Please take care not to apply too much or too little liquid gasket. Also, you should always re-apply the liquid gasket upon itself when you start and finish application. 4. Make sure that there are no gaps when reinstalling the liquid gasket parts to each other. If there are gaps between the two parts, re-apply the liquid gasket. Some parts, especially the oil pan, use the same size studs as a guide to eliminate the need for knock pin positioning etc. 5. Re-install these parts within 7 minutes of applying the liquid gasket.0A-4General InformationIf more than 7 minutes passes, remove the previous liquid gasket and re-apply it. 6. Please wait for at least 30 minutes since the last part is installed before starting the engine. Liquid gasket Seal sectionProduct nameManufacturer's nameBetween cylinder block and – Flywheel housing1207BThree BondBetween cylinder block and – Flywheel housing and – Crankcase1207BThree BondBetween cylinder block and – Crank case1207BThree BondBetween cylinder block and – Front cover1207BThree Bond262LoctiteCylinder block, head plug nipple, unit, switches • Always use the liquid gasket products listed above, or a liquid gasket identical to the ones listed above. • Use the correct quantity of liquid gasket. Always follow the handling instructions for each product. Application procedure 1. Wipe the contact surfaces clean of all water, grease or oil. The contact surfaces should be dry. 2. Apply a regular bead width of liquid gasket to one of the contact surfaces. Make sure that the bead does not break at this point. Notes: If there are special regulations concerning the application procedure in the repair document, please follow those regulations. Work procedure 1. Wipe the joint surfaces of the bolt, bolt hole, and screw thread section clean of water, grease, and oil. The contact surfaces should be dry. 2. Apply Loctite to the top 1/3 of the screw. 3. Tighten the bolt to the correct tightening torque.Important: After tightening the bolt, do not apply excessive torque or try to rotate the bolt until at least one hour has passed, and the Loctite has hardened. Procedure for using the Plastigauge TypeMeasurable rangemm (in)PG-1 (Green)0.025 – 0.076 (0.001 – 0.003)PR-1 (Red)0.051 – 0.152 (0.002 – 0.006)PB-1 (Blue)0.102 – 0.229 (0.004 – 0.009)Example: Procedure for measuring the clearance between the connecting rod bearing and crank pin. • Clean the connecting rod and bearing, and install the bearing to the rod. • Cut the plastigauge to the same width as the crank pin, and while avoiding the oil pore of the crank pin lay the gauge parallel to the pin.General Information 0A-5 • Line up the marks on the connecting rod and cap and install the crank pin, apply molybdenum disulfide to the thread section and bearing surface of the fastening bolt, and rotate both cap and bolt to the correct torque. Important: Do not move the connecting rod while using the plastigauge. • Gently remove the cap and connecting rod, and measure the crushed width of the plastigauge (clearance between rod and pin) using the scale printed on the bag.Example: Measuring the clearance between the crank bearing and crank journal • Clean the clamp face of the cylinder block and crankcase bearing, and also the bearing, and install the cylinder block to the crankcase. • Gently rest the crankshaft on the cylinder block, and rotate it approximately 30 degree to stabilize it.• Cut the plastigauge to the same size as the journal width, and while avoiding the oil pore of the journal lay the gauge parallel to the journal. • Gently rest the crank case on the cylinder block, apply molybdenum disulfide to the thread section and bearing surface of the fastening bolt, and tighten in sequence to the correct torque. Important: Do not rotate the crankshaft while using the plastigauge. • Gently remove the crankcase, and measure the crushed width of the plastigauge (clearance between bearing and journal) using the scale printed on the bag.0A-6General InformationReading the model Engine number stamping position 4HK1WSHK0185General Information 0A-7 6HK1WSHK0186General information Terminology, description of abbreviations Terminology definitions TermExplanationMaintenance standardThe generic name for reference values required for maintenance, such as nominal dimension, selection of a reference point, and limit.Nominal dimensionShows the standard value at the point of manufacture that does not include the common difference.Selection of a reference point Shows the standard value after assembling, repairing, or adjusting. Limit Front rear, left right, upper lower UnitWhen this value (dimensions) is reached, it shows that the part has reached its full limit and must be replaced or repaired. These show each orientations of parts installed to the vehicle when looking from the vehicle's forward direction. Units written to SI conventions (mainly torque, pressure, force) [Example] Length: mm, Torque: N m {kgf m}WarningItems that carry the warning mark pose a danger to life or threat of serious injury if not strictly observed.CautionItems that carry the caution mark may cause injury or lead to accidents if not strictly observed.ImportantItems that carry the important mark may cause the vehicle to break down, or may prevent the guaranteed normal operation of the system or related parts if not strictly observed.0A-8General Information TermExplanationNotesItems that should receive special mention within a work procedure.Description of abbreviations Abbreviation ACAbbreviation FWDForward ForwardF/CFuel Cut Fuel CutGNDGround EarthDescription Alternating Current Alternating CurrentACCAccessory AccessoryACGAlternating Current Generator Alternating current generatorICAPIAmerican Petrol Institute American Petroleum InstituteID PlateASM (Assy) Assembly Assembly ATDCAfter Top Dead Center After Top Dead CenterBAT, BATTBattery BatteryBRG, BrgBearing BearingBKT, BRKTBracket BracketBTDC CO CONNBefore Top Dead Center Before Top Dead Center Carbon Oxide Carbon Monoxide Connector ConnectorCPUCentral Processing Unit Central processing unitC/UControl Unit Control unitDCDirect Current Direct currentDIDirect Injection Direct injectionECUEngine Control Unit / Electronic Control Unit Engine control unit / control unitDescriptionIN ISOI/PUMP JISIntegrated Circuit Integrated circuit Identification plate Identification plate, ID plate Intake, Intake Intake International Standardization International StandardizationforOrganizationforInjection Pump Injection Pump Japanese Industrial Standard Japanese Industrial StandardL/H, LHLeft Hand Left hand sideM/VMagnetic Valve Magnetic valveNOxNitrogen Oxide Nitrogen OxideN-TDCOrganizationNumber - Top Dead Center Top dead center rotational frequencyOPTOption OptionPPole(S) PolePCVPump Control Valve/ Positive Crankcase Ventilation Pump control valve/ Positive crankcase ventilationPMParticulate Matter Particulate matterPSPre-Stroke Pre-strokeECMEngine Control Module Engine control moduleEGRExhaust Gas Recirculation Exhaust gas recirculationPTOPower Take Off Power take offExhaust ExhaustQOSQuick On System Rapid preheating systemExh, EXH Ft, FRTFront FrontRr, RRRear RearGeneral Information 0A-9 Abbreviation R/H, RHSI (International System of Units)DescriptionWith regards the conversion to SI (International System of Units)Right Hand Right hand sideR/LRelay RelaySTDStandard StandardSWSwitch SwitchTICSTiming & Injection rate Control System A type of injection systemVGS TurboVariable Geometry turbocharger System Adjustable turbo, VGS turboW/LThe introduction of the SI systems aims to internationally unify the metric system and the various units used by different countries (traditional weights and measures, the foot pound method etc.), and to curb the confusion that occurs between the different units (conversion calculations etc.). The new calculating method which adopted SI units was completely adopted in Japan in 1992, and is standardized by JIS-Z-8203. All of the units in this manual are written in line with the International System of Units SI units, and conventional units are written in { } brackets. SI French) Abbreviated name of Le Systeme International d’UnitesWarning Lamp Warning lampConnection between main SI units and conventional units SIConventional UnitLengthmmSame as the conventional unitWeight (Mass)kgkgSame as the conventional unitForceN* kg, kgfTorqueNm* kg m, gf mPressurePa*kg/cm2, mmHgDynamic force, horsepowerWPSCapacity, air volume displacementm3Litle, L, ccg/(kW h)g/(PS h)Fuel consumption*1 Published service data may conveniently use kg for force and mass (weight) instead of kgf. *2 Some conversion results may be rounded off to 1 or 2 decimal places. Converting expressions of quantity When converting, prefixes such as k (kilo) or m (mili) are used. MMega1061,000,000kKilo1031,000hHecto102100dDeci10-10.1cCenti10-20.01mMilli10-30.001Micro10-60.000001• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa • 40 mmHg = 5,332 Pa = 5.3 kPaItem, unit conversion1 kgf = 9.80665 N 1 kgf m = 9.80665 N m 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa 1 PS = 0.74 kW 1 Litle = 1 dm3, 1 cc = 1mLitle = 1cm3 1 g/(PS h) = 1.360 g/(kW h)Conversion formula Length • km 0.6214 = mile • m 3.281 = ft • mm 0.03937 = in Pressure • kPa 0.0101972 = kg/cm2 • kPa 0.145038 = psi • MPa 10.197162 = kg/cm2 • MPa 145.03774 = psi Tightening torque • N m 0.101972 = kg m • N m 0.737562 = lb ft Speed • kg/h 0.6214 = MPH Temperature • C 1.8 + 32 = FThank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITINGNOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.0A-10 General Information Table of standard Isuzu tightening torque The tightening torque values in the table below apply to all situations unless a special tightening torque is specified. Isuzu standard bolts, nuts N m {kgf m} Strength classification4.8 4TBolt head Hexagon head bolt section shape * M107TFlange boltHexagon head boltFlange bolt1.519.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1}M121.2549.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}* M121.7545.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6}68.1 ~ 102.1 {6.9 ~ 10.4}1.576.5 ~ 114.7 {7.8 ~ 11.7}83.0 ~ 124.5 {8.5 ~ 12.7}93.2 ~ 139.3 {9.5 ~ 14.2}100.8 ~ 151.1 {10.3 ~ 15.4}271.6 ~ 106.9 {7.3 ~ 10.9}77.2 ~ 115.8 {7.9 ~ 11.8}88.3 ~ 131.4 {9.0 ~ 13.4}94.9 ~ 142.3 {9.7 ~ 14.5}1.5104.0 ~ 157.0 {10.6 ~ 16.0}115.6 ~ 173.3 {11.8 ~ 17.7}135.3 ~ 204.0 {13.8 ~ 20.8}150.1 ~ 225.2 {15.3 ~ 23.0}2100.0 ~ 149.1 {10.2 ~ 15.2}109.4 ~ 164.2 {11.2 ~ 16.7}129.4 ~ 194.2 {13.2 ~ 19.8}142.5 ~ 213.8 {14.5 ~ 21.8}M181.5151.0 ~ 225.6 {15.4 ~ 23.0}—195.2 ~ 293.2 {19.9 ~ 29.9}—* M182.5151.0 ~ 225.6 {15.4 ~ 23.0}—196.1 ~ 294.2 {20.0 ~ 30.0}—M201.5206.0 – 310.0 {21.0 ~ 31.6}—269.7 ~ 405.0 {27.5 ~ 41.3}—* M202.5190.2 ~ 286.4 {19.4 – 29.2}—249.1 ~ 374.6 {25.4 ~ 38.2}—M221.5251.1 – 413.8 {25.6 ~ 42.2}—362.8 ~ 544.3 {37.0 ~ 55.5}—* M222.5217.7 ~ 327.5 {22.2 ~ 33.4}—338.3 ~ 507.0 {34.5 ~ 51.7}—M242358.9 ~ 539.4 {36.6 ~ 55.0}—430.5 ~ 711.0 {43.9 ~ 72.5}—* M243338.3 ~ 507.0 {34.5 ~ 51.7}—406.0 ~ 608.0 {41.4 ~ 62.0}—M14 * M14 M16 * M16The * mark indicates where soft materials have been used for internal thread sections, such as castings.General Information0A-11N m {kgf m} Strength classification Bolt head shapesection9.8 9T8.8 Hexagon head boltFlange boltHexagon head boltFlange bolt5.6 ~ 11.2 {0.6 ~ 1.1}6.6 ~ 12.2 {0.6 ~ 1.2}——13.4 ~ 25.7 {1.4 ~ 2.6}15.3 ~ 28.4 {1.6 ~ 2.9}16.7 ~ 30.4 {1.7 ~ 3.1}18.1 ~ 33.6 {1.9 ~ 3.4}1.2531.3 ~ 52.5 {3.2 ~ 5.4}35.4 ~ 58.9 {3.6 ~ 6.1}37.3 ~ 62.8 {3.8 ~ 6.4}42.3 ~ 70.5 {4.3 ~ 7.2}1.531.3 ~ 51.4 {3.2 ~ 5.2}34.5 ~ 57.5 {3.5 ~ 5.8}36.3 ~ 59.8 {3.7 ~ 6.1}40.1 ~ 66.9 {4.1 ~ 6.8}M121.2569.3 ~ 104.0 {7.1 ~ 10.6}77.7 ~ 116.5 {7.9 ~ 11.9}75.5 ~ 113.8 {7.7 ~ 11.6}85.0 ~ 127.5 {8.7 ~ 13.0}* M121.7564.8 ~ 96.1 {6.6 ~ 9.8}71.4 ~ 107.2 {7.3 ~ 10.9}71.6 ~ 106.9 {7.3 ~ 10.9}79.5 ~ 119.2 {8.1 ~ 12.2}1.5106.2 ~ 158.8 {10.8 ~ 16.2}114.9 ~ 172.3 {11.7 ~ 17.6}113.8 ~ 170.6 {11.6 ~ 17.4}123.4 ~ 185.1 {12.6 ~ 18.9}2100.6 ~ 149.8 {10.3 ~ 15.3}108.2 ~ 162.2 {11.1 ~ 16.6}106.9 ~ 160.0 {10.9 ~ 16.3}115.5 ~ 173.3 {11.8 ~ 17.7}1.5154.3 ~ 232.5 {15.7 ~ 23.7}171.1 ~ 256.7 {17.4 ~ 26.2}160.0 ~ 240.3 {16.3 ~ 24.5}176.9 ~ 265.3 {18.0 ~ 27.1}2147.6 ~ 221.4 {15.0 ~ 22.6}162.5 ~ 243.8 {16.6 ~ 24.9}153.0 ~ 229.5 {15.6 ~ 23.4}168.5 ~ 252.7 {17.2 ~ 25.8}M181.5222.5 ~ 334.3 {22.7 ~ 34.1}—229.5 ~ 345.2 {23.4 ~ 35.2}—* M182.5223.6 ~ 335.4 {22.8 ~ 34.2}—230.5 ~ 346.2 {23.6 ~ 35.3}—M201.5307.4 ~ 461.7 {31.4 ~ 47.1}—316.8 ~ 475.6 {32.3 ~ 48.5}—* M202.5284.0 ~ 472.1 {29.0 ~ 43.5}—293.2 ~ 440.3 {29.2 ~ 44.9}—M221.5413.6 ~ 620.5 {42.2 ~ 63.3}—424.6 ~ 636.5 {43.3 ~ 64.9}—* M222.5385.7 ~ 578.0 {39.3 ~ 58.9}—394.2 ~ 592.3 {40.0 ~ 60.4}—M242490.8 ~ 810.5 {50.0 ~ 82.7}—554.1 ~ 830.6 {56.5 ~ 84.7}—* M243462.8 ~ 693.1 {47.2 ~ 70.7}—520.7 ~ 781.6 {53.1 ~ 79.7}—M61M81.25M10 * M10M14 * M14 M16 * M16The * mark indicates where soft materials have been used for internal thread sections, such as castings.0A-12 General Information Designations for Isuzu standard bolt headsLegend 1. Hexagon head bolt(4.8, 4T) 2. Hexagon head bolt(4.8, 4T) 3. Flange bolt(4.8, 4T) 4. Flange bolt(4.8, 4T) 5. Hexagon head bolt(7T) 6. Flange bolt(7T) 7. Hexagon head bolt (refined 8.8) 8. Hexagon head bolt (refined 8.8)9. 10. 11. 12. 13. 14. 15. 16.Hexagon head bolt(Un-refined 8.8) Hexagon head bolt(Un-refined 8.8) Flange bolt(8.8) Flange bolt(8.8) Hexagon head bolt(9.8, 9T) Hexagon head bolt(9.8, 9T) Flange bolt(9.8, 9T) Flange bolt(9.8, 9T)Flare nut Pipe diameterFlare nut tightening torque (service standard value) N m {kgf m}tightening torque (for medium and large size vehicles)Flare nut 2 side width (mm) OldNew4.76 mm12.8 ~ 18.6 {1.3 ~ 1.9}14146.35 mm23.5 ~ 49 {2.4 ~ 5.0}17178.0 mm23.5 ~ 49 {2.4 ~ 5.0}191710.0 mm44.1 ~ 93.2 {4.5 ~ 9.5}221912.0 mm58.8 ~ 137.3 {6.0 ~ 14.0}272415.0 mm78.5 ~ 156.9 {8.0 ~ 16.0}3030General Information 0A-13 Taper screw from connectors (brass) N m {kgf m} Screw sizePT(R) 1/8PT(R) 1/4PT(R) 3/8PT(R) 1/12—2.0 ~ 14.7 (0.2 ~ 1.5)4.9 ~ 15.7 (0.5 ~ 1.6)9.8 ~ 16.7 (1.0 ~ 1.7)9.8 ~ 17.7 (1.0 ~ 1.8)Special Tool Classification A; Essential tool Servicing operation cannot be done with any other tools than the essential tool. B; Recommended tool Servicing work can be done with a general-purpose tool commercially available. However, it is advisable to use the recommended tool as much as possible for a reduced work time and an improved safety in work operations. C; Available tool Although it takes a more working time, servicing operations can be made with a tool commercially available as substitute for the available tool.
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